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EVOLUTION OF DCS
Different stages of evolution of Control system are :
Manual or Field control Pneumatic Single loop control system. Electronic single loop control system Centralized control system Distributed control system.
Devices
Same
Communication Loop.
ARCHITECTURES OF DCS
The master less deterministic type on single network (Node Server) The client server type with master less characteristic
on single network
The client server type with server as master and
NODE SERVER
A network with deterministic master less type of protocol has a real master less node hierarchy, which means that all the nodes, i.e., all controllers as well as operator stations will have the same priority and shall be always communicating to the network together. In this case, the failure of any one operator station, i.e. any one node will lead to the non operation of that node only and the rest of the system stays healthy , thereby maintaining the healthiness of the network.
Node 1
Node 2
Node 3
Node 4
Bus1 Bus2 All healthy nodes and all are at same hierarchy
Node 5 Node 6
Node 1
Node 2
Node 3
Node 4
Bus1
failure
Bus2
Node 5
Node 6
Failure of Bus-2 causes Bus-1 to take over without making any difference to nodes
failure
Bus1 Bus2
FAILURE OF A NODE WILL LEAD TO THE FAILURE OF THE PARTICULAR NODE ONLY. OPERABILITY IS INTACT FROM ALL OTHER NODES
Server
Client 1
Client 2
Client 3
Bus1 Bus2
Client 4
Client 5
server
Client 1
Client 2
Client 3
Bus1
failure
Bus2
Server healthy means all nodes (clients) communicating to the server
Client 4
Client 5
Failure of Bus-2 causes Bus-1 to take over without making any difference to nodes
Server
Client 1
Client 2
Client 3
Failure
Bus1 Bus2
Client 4
Client 5
Even after failure of server, the clients keep communicating in between and hence operability is intact
Client 1
Client 2
Client3
server
Network I /Bus1
Network I /Bus2
Client 1
Client 2
Client3
server
Network I /Bus1
failure
Network I /Bus2
Failure of Bus-1 causes Bus-2 to take over without making any difference to nodes
Network II /Bus1 Network II /Bus2 Client 4 Client 5
Client 1
Client 2
Client3
Data lost
server failure
Data lost
Failure of the server will lead to failure of complete network and loss of operability
Client 4
Client 5
2
3 4
One(1)
One(1) Five(5)
Common section
EWS OWS
The EWS & OWS are also to Ethernet switch through O- NET cable.
DATA FLOW
O-NET
NODE-9 NODE-8 NODE-7 NODE-6
LINE-1 LINE-2
NODE-10
NODE-5
ITC
ITC
ITC
ITC
ITC
ITC
NIS
NIS
NIS
NIS
NIS
NIS
REDUNDENT C - NET
NIS NPM
NODE-1 BOILER-1 BOILER-2 NODE -2 BOILER-3 NODE -3 COMMON
NIS NPM
NIS NPM
NIS NPM
NODE-4
C-NET
C-NET is a unidirectional, high speed serial data network that operates at a 10 megahertz communication rate. It supports a central network with up to 250 system NODE connections.
SYSTEM CARDS
THERE ARE DIFFERENT TYPES OF CARDS IN SYSTEM PANEL FOR VARIETIES OF INPUTS/OUTPUTS1)TEMPERATURE CARD FOR THERMOCOUPLE/RTD,( IMAS123)
2)ANALOG INPUT CARD FOR 4-20 ma, (IMFEC12) 3)ANALOG OUTPUT CARD FOR 4-20 ma(IMASO11) 4)DI CARD FOR CONTACT INPUT (IMDSI 13) 5) DO CARD FOR CONTACT OUTPUT (IMDS0 14) 6) NETWORK INTERFASE SLAVE (NIS-21) 7) NETWORK PROCESS MODULE (NPM-12) 8) BRC 300 ( CONTROLLER) 9) MFP 12 ( CONTROLLER) 10) ITC- (FOR COMMUNICATING WITH THE COMPUTER)
DCS SYSTEM
4-20 mA out of smart Txs., Superimposed with hart signal, are terminated to HMS. Here, HART Signal and 4-20 mA signals are separated using patch cards. 4-20 mA goes to terminate to AI cards through DCS Marshelling cabinet. Termination of this 4-20 mA depends on whether this is field powered or system powered.
MULTIPLEXER SYSTEM
Supplied by MTL,England. Multiplexers are used for cable saving. Here non critical signals have been taken through MUX. There are four MUX stations for each boiler installed in field itself. All the twelve MUX stations having redundant supply . MUX -1 & 2 for each boiler caters mainly AI whereas MUX-3 & 4 caters mainly DI/DOS.
MULTIPLEXER SYSTEM
The MUX uses redundant EBIM (Ethernet bus interface module) processing data at very high speed of 100 Mbps, whereas the controller (MFP12) used in DCS system for third party communication is Modbus compatible, hence MOXA switches are used to convert Ethernet to Modbus.
MULTIPLEXER SYSTEM
Hence redundant Ethernet cable have been laid from each of the MUX to redundant MOXA switches from MOXA, Ethernet Cable been laid for HMS/MUX PC where WORKBENCH Software is loaded for status monitoring of all MUX modules. Also RS-485 Cable laid from MUX-1 & 2 having AIs only to HMS PC, through RS-485 to RS-232 Converter, for catering smart transmitters with the help of CORNERSTONE Software loaded on the same HMS/MUX PC.
SER-SEQUENCE OF EVENT
RECORDER
There is one SER of 512 points comprising of two SER Stations - EL1 & EL2. SER Stations EL1 DI Cards 9 No of events handling capacity 288
EL2
224
C-NET C-NET
NIS
NPM
TO FIELD
TU
SLAVE
BRC
FROM FIELD
TU
SLAVE
BRC
Sr.No. 1 2 3 4 5 6 7
Used for Automatic Boiler Controller(ABC) Burner management system(BMS) Sequence (SEQ) Turbine of TG 1 & 2. Common Section RTDS 1 & 2 EWS
Professional Based.
C - NET
RTDS1
RTDS2
EWS
O-NET
HIS P
HIS R
CLIENT
COMPOSER
CPP
Architecture is Client server based. Operating system is Windows 2000 professional based. All critical loops are not redundant . DCS is PPB based.
1 2
3 4
Data Bus Redundancy A) Power Supply B) System Bus C) Controller D) I/O Module E) Server F) Memory(system )
Yes
Yes
Yes
6 7
8 9 10 11
Online Replacement Online Configuration System Memory I/O capacity Web Connection Scan time<200ms
Yes Yes
User Defined >10000 tags posible Possible with isolation Possible
Yes Yes
User Defined Sutable for large plant Possible with isolation Possible
Yes Yes
User Defined only for medium plant Possible with isolation Possible
Yes Yes
User Defined Up to 100000 I/O Possible with isolation Possible
Yes Yes
User Defined only for medium plant Possible with isolation Possible
1 2
Client Server Window Based Window NT,XP,2000 Using LAN Up to 100 Mbps
3 4
Data Bus Redundancy A) Power Supply B) System Bus C) Controller D) I/O Module E) Server F) Memory(system)
Yes Yes Yes optional with extra Yes optional with extra
Yes Yes optional with extra optional with extra Yes Yes
Yes Yes optional with extra optional with extra Yes Yes
Yes Yes optional with extra optional with extra optional with extra optional with extra
C) Controller Memory
6 Online Replacement Online Configuration
7 8
9 10 11
System Memory
I/O capacity Web Connection Scan time<200ms
N/A Possible